Method of producing flocked sheet material



May 16, 1944. .LQFERRANTE METHOD OF PRODUCING FLOCKED SHEET MATERIAL Filed Nov. 23, 1940 2 Shees-Sheet 1 May 16 1944- J. FERRANTE METHOD 0F PRODUGING-FLOCKED SHEET MATERIAL Filed Nov. 23, 1940 2 Sheets-Sheet 2 y u HIIIIIIIH. l .IIIIH n @www Patented May 16, i944 UNITED 'sTliTEs PATENT OFFICE METHOD F PRODUCING FLOCKED SHEET MATERIAL John Ferrante, Johnstown, N. Y., assignor to Kenlea Mfg. Corporation, a corporation of New York Application November 23, 1940, Serial No. 366,908

7 Claims.

is to produce finished flocked sheets on which the Y flock is firmly attached, so that it cannot easily be removed or rubbed off, even under abnormal conditions. Another aim is to provide a novel method of making a laminated flocked sheet in lwhich a base coating of ordinary plastic Hevea rubber and a thin flock anchorage coating of vulcanizable synthetic rubber are applied so that the anchorage coating not only serves more firmly to imbed the flock, but also acts .as a protective layer to prevent deterioration of the base coat due to aging, exposure to sunlight, weathering and the solvent action of ordinary cleaning fluids, oils and greases.

This application is a continuation-impart of my copending application Ser. No. 179,030 filed December 9, 1937.

In the drawings: l

Fig. 1 is a diagrammatic view of one form of apparatus for applying and drying a base coat of Hevea rubber to a continuous sheet of fabric;

Fig. 2 is a similar view showing apparatus for applying a coating of synthetic rubber and then a layer of flock to the coated product of Fig. 1 and subsequently drying it;

Fig. 3 is an enlarged, fragmentary, sectional view of the product of Fig. 1;

Fig. 431s an enlarged, fragmentary, view of the product of Fig. 2;

Fig. 5 is a greatly enlarged, fragmentary, sectional view of the material shown in Fig. 4;

Fig. 6 is a view similar to Fig. 1 showing apparatus for applying solvent to the product of Fig. 2 and then drying and vulcanizing it to form the completed material:

Fig. '7 is a greatly enlarged. fragmentary, sectional vew of the product of Fig. 6 showing how a flock fiber is rmly imbedded in the synthetic rubber; and f Fig. 8 is a diagrammatic view of a form of apl sectional paratus for producing completed flocked ma tcrial in a continuous operation.

In the practice ofmanufacturing flocked sheet material, one of the methods employed has been to apply an adhesive coating, usually vulcanizable rubber'cement, to a continuous strip of material, dusting or shaking flock on the coating, agitating the material and subsequently curing or vulcanizing the cement binder. Several variations of this method have been used. such as removingthe excess ock by suction or the like, before vulcanization and brushing the finished surface after it is dried or is vulcanized.

It has been found that, even after vulcanizacement and may be readily scraped off, particularly if a rubber cement solvent is employed. While it is not generally intended that such drastic steps be taken to destroy the finish, it frequently happens that the flocked Surface is marred by such means. For example, it has recently been the practice to make such articles as shoe uppers, ladies handbags, gloves and the like from flocked sheet material, and such articles are subjected to much abuse, with the result that the suede like finish is ruined, particularly so should gasoline or other solvents come in contact with the surface. The present method produces a suede like finish which will withstand abnormal abuseand which may be cleaned frequently with ordinary solvents without s'loughing off.

Referring particularly to the drawings, Fig. i illustrates one form of apparatus for applying and drying a base coating of ordinary plastic, Hevea rubber to sheet material to which is subsequently applied an adhesive and -protective coating of vulcanizable synthetic rubber cement in which the flock fibers are to be imbedded. The material to be treated, such as paper, rubber, fabric or the 30 like, is preferably in the form of a roll I0 from which it is unwound and passed beneath a coating applying apparatus Il, such as is shown in the patent to Lea No. 2,073,557. The coating in this instance, is composed oi ordinary rubber cement to whichA isadded rubber solvent. It is spread in a. uniform layer en the top surface of the material to which it adheres. In the case of a knitted or woven fabric base, the cement firmly imbeds itself in the interstices thereof adhering firmly thereto and presenting an even upper surface. The coated material then passes through an ordinary drier chamber from which solvent vapor is removed by a suction fan i3 and subsequently recovered. The material, after passing through the chamber I2, is wound in the form of a roll f6 so that it can be stored or transferred to apparatu` for performing the next step in the method.

Referring to Fig. 2, the roll I 4 of Fig. 1 is ainwound and fed through a second apparatus for `coating and ocking it. In this instance` the material passes beneath a coating apparatus it.

similar to the apparatus II. This coating con'- tion, the flock is not firmly imbedded in the for further use.

have been added. Neoprene is used because of its'resistance to oils, oxidation, heat, ozone, etc. in sharp contrast to natural rubber which is detrimentally affected by such exposures. The

solvent employed with "neoprene" is different from that used in the base coating of rubber. In this instance, it comprises coal tar naphtha and a chlorinated hydrocarbon such as carbon tetrachloride. The plasticizer, in this instance, may be sulphonated.y hydrocarbon or -oil made for the purpose. Preferably about 1/2 to 1% by binder. In order that the flock may be distributed more evenly, the web is agitated by rotating beaters I8 which agitation is transferred to the sheet material and the applied ock. After leaving the ilock applying apparatus, the surplus fiock which has not adhered to the binder is removed by means of a suction nozzle I9 and reclaimed The treated material is then dried, conveniently by passing it through a heated drying chamber 20, from which the solvent vapor may be carried oi by a suction fan 2l. After leaving the drying chamber, the 'finished side of the material may be brushed by means of a rotary brush 22 mounted within a suction hood 23 to remove any flock not removed by the nozzle I9 and to give the material a softer or smoother finish. After this step, the material is shown as being wound into a roll 24 ready for storage and subsequent treatment.

Figs. 3 and 4 represent the product of Figs. 1 and 2 respectively or of the successive steps in practicing that portion of the method thus far described. In Fig. 3, the sheet S is shown as having a base coating R of rubber and in Fig. 4 a top coating N of neoprene and the nap fibers F. In'Fig.,5, a flock fiber is shown as being slightly imbedded in the "neoprene" binder. It has been found that by applying a solvent to the flocked material at this point the neoprene binder is softened and is raised upwardly around the roots of the fibers by capillary attraction, thereby increasing the depth to which the fibers are actually imbedded in the binder. Incidentally, by applying pressure to the flocked surface, the depth of penetration of the fibers into the binder is increased. 'I'he solvent ,may be clear but is preferably colored by an aniline or oil-soluble dye of the same color as that of the fiock to improve the appearance of the surface and prevent any discoloration of the dyed fibers. This is particularly true when black ock is employed because a clean solvent will give the finished flock a gray appearance. It has been found, further, that if heaijI is applied immediately after the application of solvent, the solvent is evaporated more rapidly, thereby accelerating the capillary action of the dissolved binder around the roots of the fibers. The material is subsequently vulcanized to pro-y duce a finished product.

Referring again to the drawings. one form of apparatus for accomplishing the above steps is illustrated in Fig. 6 wherein the roll 24 is shown as having its ends reversed so thatthe material is fed therefrom with the flocked side on the bottom. 'I'he material passes beneath a. .guide roll 25 and between a lower solvent applying roll 26 and an upper pressure roll 21. Both rolls are preferably vfelt covered and the lower roll is partially immersed in a trough containing neoprene'solvent 28 so that the solvent is picked up by the felt covering and applied to the flocked side of the sheet. The. solvent is thus caused to wet or penetrate the fibers and dissolve or soften some of the neoprene binder around the roots of the fibers. As before stated, the solvent is preferably colored to match the color of the flock. The roll 21 exerts pressure on the upper or back side of the material, thereby squeezing out excess solvent and simultaneously forcing the fibers deeper into the softened, uncured neoprene binder.

It has been found that if pressure is subsequently applied, the flock will be imbedded still deeper into the binder, because the solvent will have additional time to be effective. To this end, the material, after it leaves 'the rolls 26 and 21 is guided between smooth pressure rolls 29 and 30. It then passes upwardly around the upper roll 29 and over a guide roll 3I into, a drying chamber 32 wherein the temperature, is preferably maintained at about 150 F. or more, to

evaporate the remaining solvent on the material product is wound on a hatching roll 35.

Fig. 4'1 illustrates the flock fiber of Fis. 5 imbedded firmly in an upstanding. pimple-like mound of neoprene It is to be understood that the application of either the rubber base or the neoprenemay be applied and the sheet flocked, dried and iinished by the application 4of solvent and subsequent drying and vulcanization in a continuous operation. In Fig. 8, there is shown suitable apparatus for performing these operations. Assuming that the roll of material I4 has previously been coated with Hevea rubber inaccordance with the process described in connection with Fig. 1, it is coated with "neoprene" by apparatus 36; then flocked by the flocking apparatus 31 and the excess flock is sucked olf through a suction nozzle 38.y Thence, it passes through a drying chamber 39 and beneath a brush 40. The path ofthe sheet is then. reversed by passing around guide rollers 4I and 42 and between a lower solvent applying roll 43 and an upper pressure roll 44, the lower roll being immersed in a trough containing neoprene" solvent 45.` Then it passcs'through the two smooth` pressure rolls 46 and 41 better to through the drying chamber, the material is fed downwardly into and through a vulcanizing chamber 48 where the lneoprene binder and rubber base are cured and the nnished product is then wound on a hatching roll 49.

As shown in Fig. 8, the drying and vulcanizing chambers are preferably combined in a single unit: although it will be understood that they may be separated from each other as shown in Fig. 6. The vulcanizing chamber is in the lower portion of the unit and is separated from the drying chamber by a partition 50 which has a series of perforations I permitting some of the hot air to escape upwardly into the drying chamber. tt in the vulcanizing chamber will serve the double purpose oi' vulcanization and drying.

Obviously, the temperatures in the vulcanizing and drying chambers may be and-preferably are controlled automatically; but this forms no part of the present invention. They may be selected to suit the composition of the particular types` of rubber employed. It'is also to be understood that the "neoprene" solvent may be applied by any other well known method instead of using the ordinary submerged roll to transfer it from a trough. For example,- it may be sprayed directlyon the flocked surface of the sheet and the sheet subsequently subjected to pressure. It is important, however, that pressure be applied to the flocked surface as soon as the "neoprene coating is softened by its solvent and it has been found that the flock bers are more firmly. imbedded in the necprene" if the docked sheet is immediately subjected to drying heat. However. it is contemplated that, in some cases, the solvent may be applied to the material immediately after the flock is applied and the excess fioclr is removed, and while the "neoprene" is still in a dampened and somewhat softened condition. Whatever method is employed for applying the solvent, it is quite important that the flock fibers shall be partially imbedded in the uncured or tacky neoprene."

The method described in connection with Fig. a may be employed to apply a very thin coat of "neoprene without any rubber base on iightweight materials, such as gossamer fabrics, especially where thickness of the finished product is not essential. Inthat event, the neoprenel is applied in the form of a heavy dough to prevent deep penetration into the interstices of the fabric.D sThis also conserves the solvent which is mixed with the neoprene Even though the flock fibers do not penetrate the dough-like coating of neoprene as deeply as they would a more plastic, coating,v the subsequent solvent treatment insures adequate depth of penetration of the fibers to produce a good wearing surface and, at the same time, .to impart a soft draping effect to the`flocked surface.

Obviously. the method is not dependent upon the particular apparatus herein shown and described. Neither is the invention limited to a strict conformity to the described steps, but is capable of many variations 1without departing from the spirit thereof.

What is claimed is: o 1. The process of flocking sheet material with fibers to produce a suede-like finish. which comerate the capillary action of the Idissolved neo-v prene on the roots of the flock fibers; and subsequently vulcanizing the rubber and the neoprene coating. l

Thus, a single set of heating coilsv 2. The process of flocking sheet material with fibers to produce a suede-like finish. which comprises applying a base coating. of Hevea rubber cement to one face of the material; subjecting the base coating to drying heat; then applying a thin coating of plasticized "neoprene" cement to the base coating; applying flock to the neoprene" coating; again subjecting the material to drying heat and removing excess dock; wetting the oclred surface with a "neoprene solvent .and subjecting the noch fibers to penetrating pressure; immediately subjecting the wetted surface to drying heat; and nally vulcanizing the said coatings.

3. The process of flocking sheet material with fibers to produce a suede-like finish, which comprises continuously feeding the material through a machine; applying ordinary rubber cement to the surface; then applying a thin coat of neoprene; applying noch to the neoprene surface; removing encessnoclr; drying the necked material; applying va. solvent for the neoprene directly to the flocked surface; heatingthe moving material as it is delivered from 4the machine to evaporate the solvent and accelerate the capillary action of the dissolved "neoprenel on the roots of the flock bers; vulcanizing said coatings; 'and winding the finished material on a hatching roll.

4. The process of hooking sheet material with fibers to produce a suede-like finish; which comprises continuously feeding the material through a machine; applying plasticized neoprene to the surface; applying flock to the "neoprene";

A removing excess flock; drying the flocked material; applying a solvent for the neoprene directly to the flocked surface; heating 'the moving sheet of material to evaporate the solvent and accelerate the capillary action of the dissolved neoprene" on the roots of the flock bers; removing the solvent vaporsfrom the material by suction during the successive drying operations; vulcanizing the "neoprene coating; and winding the finished material on a hatching roll.

5. That method of treating fiber necked sheet material having a neoprene coating which is characterized by applying sufficient neoprene solvent to the flocked surface to penetrate the exposed fibers and dissolve some of the neoprene at the roots of the fibers to increase the -depth of penetration of the fibers in the binder by capillary action; applying pressure to the material better to x the bers in thel softened neoprene" coating; and then subjecting the sheet to solvent vaporlzing heat to remove the f coating which is characterized by applying directly to the flocked surface sufficient "neoprene solvent having a fast dye of the same color as the flock mixed therewith to penetrate the exposed fibers and dissolve some ofthe neoprene at the roots of the fibers to increase the depth of penetration of the fibers in the coating by capillaryy action; and then subjecting the sheet to solvent vaporizing heat to remove the solvent and simultaneously accelerate the capillary action of the dissolved nenni-ene" on the ber roots, so that Athe materia! is ready to canized.

v. That method of treating aber docked sheet binder by capillary action: immediately subjectmateriai having a neoprene binder which is 'ing the sheet to solvent vaporizing heat to accelcharacterized by applying sumcient neoprene" erate the capillary action; and finally vulcanixins solvent directly to the ocked surface to penethe neoprene" by passing it through a heated trate the exposed bers land dissolve some of the 6 vuicanizing chamber in a continuous operation.

. neoprene at the roots of the bers to increase the depth of penetLation of the fibers in the JOHN FERRANTE. 

